SECTION 2 STRUCTURE AND FUNCTION

Group 1 Pump Device 2-1

Group 2 Main Control Valve 2-22
Group 3 Swing Device 2-50
Group 4 Travel Device 2-62
Group 5 RCV Lever 2-75
Group 6 RCV Pedal 2-82
 SECTION 2 STRUCTURE AND FUNCTION
GROUP 1 PUMP DEVICE
1. STRUCTURE
The pump device consists of main pump, regulator and gear pump.

Port Port name Port size

A1,2 Delivery port SAE6000psi 1"
B1 Suction port SAE2500psi 3"
Dr Drain port PF 3/4 - 23
Pi1,i2 Pilot port PF 1/4 - 15
Pm1,m2 Qmax cut port PF 1/4 - 15
Psv1,sv2 Servo assist port PF 1/4 - 15
a1,2,3,4,5 Gauge port PF 1/4 - 15
A3 Gear pump delivery port PF 1/2 - 19
B3 Gear pump suction port PF 3/4 - 20.5
PB Gauge port PT1/8
36072MP01

2-1
1) MAIN PUMP(1/2)
The main pump consists of two piston pump(front & rear) and valve block.

36072MP02

04 Gear pump 271 Pump casing 706 O-ring

111 Drive shaft(F) 311 Valve cover(F) 710 O-ring
113 Drive shaft(R) 312 Valve cover(R) 717 O-ring
114 Spline coupling 313 Valve plate(R) 719 O-ring
123 Roller bearing 314 Valve plate(L) 724 O-ring
124 Needle bearing 401 Hexagon socket bolt 725 O-ring
127 Bearing spacer 402 Hexagon socket bolt 728 O-ring
130 Booster 406 Hexagon socket bolt 732 O-ring
012 Cylinder block 466 VP Plug 774 Oil seal
151 Piston 468 VP Plug 789 Back up ring
152 Shoe 490 Plug 792 Back up ring
153 Set plate 492 Plug 808 Hexagon head nut
156 Bushing 531 Tilting pin 824 Snap ring
157 Cylinder spring 532 Servo piston 885 Pin
211 Shoe plate 534 Stopper(L) 886 Spring pin
212 Swash plate 535 Stopper(S) 901 Eye bolt
214 Bushing 548 Feedback pin 953 Set screw
251 Support plate 702 O-ring 954 Adjust screw
261 Seal cover(F)

2-2
2) FRONT REGULATOR(1/2)

36072RE01

Port Port name Port size

Pi1,Pi2 Pilot port PF 1/4-15

Psv1,Psv2 Servo assist port PF 1/4-15

2-3
 FRONT REGULATOR(2/2)

36072RE02

408 Hexagon socket bolt 628 Adjust screw(C) 724 O-ring

412 Hexagon socket bolt 629 Cover(C) 725 O-ring
413 Hexagon socket bolt 630 Lock nut 728 O-ring
436 Hexagon socket bolt 631 Sleeve, pf 730 O-ring
438 Hexagon socket bolt 641 Pilot cover 732 O-ring
466 Plug 642 Adjust screw(QMC) 733 O-ring
496 Plug 643 Pilot piston 734 O-ring
541 Seat 644 Spring seat(Q) 735 O-ring
543 Stopper 645 Adjust stem(Q) 755 O-ring
545 Steel ball 646 Pilot spring 756 O-ring
601 Casing 647 Stopper 763 O-ring
611 Feedback lever 648 Piston(QMC) 801 Hexagon nut
612 Lever(1) 651 Sleeve 814 Snap ring
613 Lever(2) 652 Spool(A) 836 Stop ring
614 Center plug 653 Spring seat 858 Snap ring
615 Adjust plug 654 Return spring 874 Pin
621 Compensator piston 655 Set spring 875 Pin
622 Piston case 696 Port cover 887 Pin
623 Compensator rod 697 Check valve plate 897 Pin
624 Spring seat(C) 708 O-ring 898 Pin
625 Outer spring 722 O-ring 924 Set screw
626 Inner spring 723 O-ring 925 Adjust screw(QI)
627 Adjust stem(C)

2-4
3) REAR REGULATOR(1/2)

36072RE03

Port Port name Port size

Pi1,Pi2 Pilot port PF 1/4-15

Psv1,Psv2 Servo assist port PF 1/4-15

2-5
 REAR REGULATOR(2/2)

36072RE04

079 EPPR valve 627 Adjust stem(C) 724 O-ring

407 Hexagon socket bolt 628 Adjust screw(C) 725 O-ring
412 Hexagon socket bolt 629 Cover(C) 728 O-ring
413 Hexagon socket bolt 630 Lock nut 730 O-ring
436 Hexagon socket bolt 631 Sleeve, pf 732 O-ring
438 Hexagon socket bolt 641 Pilot cover 733 O-ring
482 Plug 642 Adjust screw(QMC) 734 O-ring
496 Plug 643 Pilot piston 735 O-ring
541 Seat 644 Spring seat(Q) 755 O-ring
543 Stopper 645 Adjust stem(Q) 756 O-ring
545 Steel ball 646 Pilot spring 763 O-ring
601 Casing 647 Stopper 801 Hexagon nut
611 Feedback lever 648 Piston(QMC) 814 Snap ring
612 Lever(1) 651 Sleeve 836 Stop ring
613 Lever(2) 652 Spool(A) 858 Snap ring
614 Center plug 653 Spring seat 874 Pin
615 Adjust plug 654 Return spring 875 Pin
621 Compensator piston 655 Set spring 887 Pin
622 Piston case 697 Check valve plate 897 Pin
623 Compensator rod 699 Port cover 898 Pin
624 Spring seat(C) 708 O-ring 924 Set screw
625 Outer spring 722 O-ring 925 Adjust screw(QI)
626 Inner spring 723 O-ring

2-6
4) GEAR PUMP

36072GP01

307 Poppet 353 Drive gear 466 Plug

308 Seat 354 Driven gear 700 Ring
309 Ring 355 Filter 710 O-ring
310 Spring 361 Front case 725 O-ring
311 Screw 433 Flange socket 732 O-ring
312 Lock nut 434 Flange socket 850 Snap ring
351 Gear case 435 Flange socket

2-7
2. FUNCTION
1) MAIN PUMP
The pumps may classified roughly into the rotary group performing a rotary motion and working as
the major part of the whole pump function: the swash plate group that varies the delivery rates: and
the valve cover group that changes over oil suction and discharge.

(1) Rotary group

The rotary group consists of drive shaft
(F)(111), cylinder block(141),piston
shoes(151,152), set plate(153), spherical 124
313
bush(156), spacer(158) and cylinder 141
spring(157). The drive shaft is supported 158
151 156
by bearing(123,124) at its both ends. 152 153
The shoe is caulked to the piston to form
111
a spherical coupling. It has a pocket to 157
relieve thrust force generated by loading 123
211
pressure and to take hydraulic balance so
that it slides lightly over the shoe
plate(211). The sub group composed by
a piston and a shoe is pressed against the
shoe plate by the action of the cylinder
spring via a retainer and a spherical bush.
Similarly, the cylinder block is pressed
against valve plate(313) by the action of
the cylinder spring.
(2) Swash plate group 531
The swash plate group consists of swash 548
plate(212), shoe plate(211), swash plate 214
support(251), tilting bush(214), tilting
pin(531) and servo piston(532). 212
The swash plate is a cylindrical part 251 211
formed on the opposite side of the sliding
surface of the shoe and is supported by
the swash support.
If the servo piston moves to the right and
532 α
left as hydraulic force controlled by the
regulator is admitted to hydraulic chamber
located on both sides of the servo piston,
the swash plate slides over the swash α
plate support via the spherical part of the
tilting pin to change the tilting angle( ).

2-8
(3) Valve cover group
The valve cover group consists of valve
cover(F, 311), valve cover(R, 312), valve
plate (313, 314), spline coupling (114),
booster (130) and valve plate pin (885).
The valve plate having two melon-shaped
314
ports is fixed to the valve block and feeds 312
and collects oil to and from the cylinder
block. 130
The oil changed over by the valve plate is 114
885
connected to an external pipeline by way 311
of the valve block.
Now, if the drive shaft is driven by a prime
mover(electric motor, engine, etc), it
rotates the cylinder block via a spline
linkage at the same time. If the swash
plate is tilted as in Fig(previous page) the 885
313
pistons arranged in the cylinder block
make a reciprocating motion with respect
to the cylinder block, while they revolve
with the cylinder block.
If you pay attention to a single piston, it
performs a motion away from the valve
plate(oil sucking process) within 180
degrees, and makes a motion towards the
valve plate(or oil discharging process) in
the rest of 180 degrees. When the
swash plate has a tilting angle of zero, the
piston makes no stroke and discharges
no oil.

2-9
2) REGULATOR
Regulator consists of the negative flow control, total horse power control, power shift control and
cut-off function.

(1) Negative flow control

By changing the pilot pressure Pi, the
pump tilting angle(delivery flow) is
regulated arbitrarily, as shown in the
figure.
This regulator is of the negative flow

Delivery flow, Q
control in which the delivery flow Q
decreases as the pilot pressure Pi rises.
With this mechanism, when the pilot
pressure corresponding to the flow
required for the work is commanded, the
pump discharges the required flow only,
and so it does not consume the power Pilot pressure, Pi
uselessly.

2-10
① Flow reducing function

643 654 651 652 613 646

P1 CL
B(E)
874
897
C
A

875

611

Servo piston Small diameter

Large diameter D chamber
chamber 548
531

R210LC-7 (2-10)

As the pilot pressure Pi rises, the pilot piston(643) moves to the right to a position where the
force of the pilot spring(646) balances with the hydraulic force.
The groove(A) in the pilot piston is fitted with the pin(875) that is fixed to lever 2(613). Therefore,
when the pilot piston moves, lever 2 rotates around the fulcrum of point B [fixed by the fulcrum
plug(614) and pin(875)]. Since the large hole section(C) of lever 2 contains a protruding
pin(897) fixed to the feedback lever(611), the pin(897) moves to the right as lever 2 rotates.
Since the opposing-flat section(D) of the feedback lever is fitted with the pin(548) fixed by the
tilting pin(531) that swings the swash plate, the feedback lever rotates around the fulcrum of
point D, as the pin(897) moves.
Since the feedback lever is connected with the spool(652) via the pin(874), the spool moves to
the right.
The movement of the spool causes the delivery pressure P1 to connect to port CL through the
spool and to be admitted to the large diameter section of the servo piston. The delivery
pressure P1 that is constantly admitted to the small diameter section of the servo piston moves
the servo piston to the right due to the area difference, resulting in decrease of the tilting angle.
When the servo piston moves to the right, point D also moves to the right. The spool is fitted
with the return spring(654) and is tensioned to the left at all times, and so the pin(897) is pressed
against the large hole section(C) of lever 2.
Therefore, as point D moves, the feedback lever rotates around the fulcrum of point C, and the
spool is shifted to the left. This causes the opening between the sleeve(651) and spool(652) to
close slowly, and the servo piston comes to a complete stop when it closes completely.

2-11
② Flow increasing function

643 654 651 652 613 646

P1 CL
B(E)
874
897
C

875
611

Small diameter
Servo piston D chamber
Large diameter 548
chamber
531

R210LC-7 (2-11)

As the pilot pressure Pi decreases, the pilot piston(643) moves to the left by the action of the pilot
spring(646) and causes lever 2(613) to rotate around the fulcrum of point B. Since the pin(897)
is pressed against the large hole section(C) of lever 2 by the action of the return spring(654) via
the spool(652), pin(874), and feedback lever(611), the feedback lever rotates around the fulcrum
of point D as lever 2 rotates, and shifts the spool to the left. Port CL opens a way to the tank
port as the spool moves. This deprives the large diameter section of the servo piston of
pressure, and shifts the servo piston to the left by the discharge pressure P1 in the small
diameter section, resulting in an increase in the flow rate.
As the servo piston moves, point D also moves to the left, the feedback lever rotates around the
fulcrum of point C, and the spool moves to the right till the opening between the spool and sleeve
is closed.

2-12
③ Adjustment of flow control characteristic
The flow control characteristic can be
adjusted with the adjusting screw.
Adjust it by loosening the hexagon 801
924
nut(801) and by tightening(or loosening)
the hexagonal socket head screw(924).
Tightening the screw shifts the control
chart to the right as shown in the figure.
※ Adjusting values are shown in table.

Adjustment of flow control

characteristic R290RE08(1)
Speed
Tightening Flow control Flow change
amount of control change
adjusting starting amount

Delivery flow, Q
screw(924) pressure
change
amount

(min -1) (Turn) (kgf/cm2) (ℓ/min)

1900 +1/4 +1.7 +20

Pilot pressure, Pi

2-13
(2) Total horsepower control
The regulator decreases the pump tilting
angle(delivery flow) automatically to limit
the input torque within a certain value with

Delivery flow, Q
a rise in the delivery pressure P1 of the
self pump and the delivery pressure P2 of
the companion pump.
(The input horsepower is constant when
the speed is constant.)
Since the regulator is of the simul taneous
total horsepower type that operates by the Delivery pressure, (P1+P2)
sum of load pressures of the two pumps
in the tandem double-pump system, the
prime mover is automatically prevented
from being overloaded, irrespective of the
load condition of the two pumps, when
horsepower control is under way.
Since this regulator is of the simultaneous
total horsepower type, it controls the tilting
angles(displacement volumes) of the two
pumps to the same value as represented
by the following equation :
Tin = P1×q/2 + P2×q/2
= (P1+P2)×q/2
The horsepower control function is the
same as the flow control function and is
summarized in the following.(For detailed
behaviors of respective parts, refer to the
section of flow control).

2-14
① Overload preventive function

621 651 652 623 612 601 625 626

CL
B(E)
897

P2 P1
875

611

Large diameter Servo piston

chamber Small diameter
D chamber

R130RE01

When the self pump delivery pressure P1 or the companion pump delivery pressure P2 rises, it
acts on the stepped part of the compensating piston(621). It presses the compensating
rod(623) to the right till the force of the outer spring(625) and inner spring(626) balances with the
hydraulic force. The movement of the compensating rod is transmitted to lever 1 via pin (875).
Lever 1 rotates around the pin(875) (E) fixed to the casing(601).
Since the large hole section(F) of lever 1 contains a protruding pin(897) fixed to the feedback
lever(611), the feedback lever rotates around the fulcrum of point D as lever 1 rotates, and then
the spool(652) is shifted to the right. As the spool moves, the delivery pressure P1 is admitted to
the large diameter section of the servo piston via port CL, causes the servo piston move to the
right, reduces the pump delivery flow rate, and prevents the prime mover from being overloaded.
The movement of the servo piston is transmitted to the feedback lever via point D. Then the
feedback lever rotates around the fulcrum of point F and the spool is shifted to the left. The
spool moves till the opening between the spool and sleeve(651) is closed.

2-15
② Flow reset function

621 651 652 623 612 601 625 626

P1 CL
B(E)
897

P2 P1

875

Large diameter Small diameter

chamber Servo piston D chamber

R130RE11

As the self pump delivery pressure P1 or the companion pump delivery pressure P2 decreases,
the compensating rod(623) is pushed back by the action of the springs(625 & 626) to rotate lever
1(612) around point E. Rotating of lever 1 causes the feedback lever(611) to rotate around the
fulcrum of point D and then the spool(652) to move to the left. As a result, port CL opens a way
to the tank port.
This causes the servo piston to move to the left and the pump's delivery rate to increase.
The movement of the servo piston is transmitted to the spool by the action of the feedback
mechanism to move it till the opening between the spool and sleeve is closed.

2-16
③ Low tilting angle(low flow) command preferential function
As mentioned above, flow control and horsepower control tilting angle commands are transmitted
to the feedback lever and spool via the large-hole sections(C & F) of levers 1 and 2. However,
since sections C and F have the pins(Ø4) protruding from the large hole(Ø8), only the lever
lessening the tilting angle contacts the pin(897) ; the hole(Ø8) in the lever of a larger tilting angle
command is freed without contacting the pin(897). Such a mechanical selection method permits
preference of the lower tilting angle command of the flow control and horsepower control.
④ Adjustment of input horsepower
Since the regulator is of total cumulative horsepower type, adjust the adjusting screws of both the
front and rear pumps, when changing the horsepower set values. The pressure change values
by adjustment are based on two pumps pressurized at the same time, and the values will be
doubled when only one pump is loaded.
a. Adjustment of outer spring 625 626 630 628
Adjust it by loosening the hexagon
nut(630) and by tightening(or loosening)
the adjusting screw C(628). Tightening
801
the screw shifts the control chart to the
right and increases the input 925
horsepower as shown in the figure.
Since turning the adjusting screw C by
N turns changes the setting of the inner
spring(626), return the adjusting screw
CI(925) by N×A turns at first.(A=1.9)
※ Adjusting values are shown in table.
R290RE08(2)
Adjustment of outer spring
Speed
Tightening Compens- Input torque
amount of ating control change
adjusting starting amount
Delivery flow, Q

screw(C) pressure
(628) change
amount

(min -1) (Turn) (kgf/cm2) (kgf m)

1900 +1/4 +18 +8

Delivery pressure, (P1+P2)

2-17
b. Adjustment of inner spring
626
Adjust it by loosening the hexagon nut
(801) and by tightening(or loosening)
the adjusting screw QI(925).
Tightening the screw increases the flow 801
and then the input horsepower as
925
shown in the figure.
※ Adjusting valves are shown in table.

Adjustment of inner spring

Speed
Tightening Compens- Input torque
amount of ating control change R290RE08(3)
adjusting starting amount
screw(QI) pressure
(925) change
amount

Delivery flow, Q
(min -1) (Turn) (kgf/cm2) (kgf m)

1900 +1/4 +15 +7

Delivery pressure, (P1+P2)

2-18
(3) Power shift control

621 651 652 623 612 625 626

898 P1 CL
B(E)
897

Pf
P2 P1
875

611

Large diameter Small diameter

chamber Servo piston D chamber

R130RE13)

The set horsepower valve is shifted by varying

the command current level of the proportional
pressure reducing valve attached to the pump.
Delivery flow, Q

Only one proportional pressure reducing valve

is provided. Pf=
MIN
However, the secondary pressure Pf (power Pf= .
MA
shift pressure) is admitted to the horsepower X.
control section of each pump regulator through
the pump's internal path to shift it to the same Delivery pressure, (P1+P2)
set horsepower level.
This function permits arbitrary setting of the pump output power, thereby providing the optimum
power level according to the operating condition.
The power shift pressure Pf controls the set horsepower of the pump to a desired level, as
shown in the figure.
As the power shift pressure Pf rises, the compensating rod(623) moves to the right via the
pin(898) and compensating piston(621).
This decreases the pump tilting angle and then the set horsepower in the same way as
explained in the overload preventive function of the horsepower control. On the contrary, the set
horsepower rises as the power shift pressure Pf falls.

2-19
(4) Adjustment of maximum and minimum flows
① Adjustment of maximum flow
808
Adjust it by loosening the hexagon
nut(808) and by tightening(or loosening) 954
the set screw(954).
The maximum flow only is adjusted
without changing other control
characteristics.
R290RE08(5)

Adjustment of max flow spring

Speed
Tightening amount Flow change

Delivery flow, Q
of adjusting screw amount
(954)

(min -1) (Turn) (ℓ/min)

1900 +1/4 -7
Delivery pressure, Pi

② Adjustment of minimum flow

Adjust it by loosening the hexagon
nut(808) and by tightening(or loosening)
the hexagonal socket head set screw 808
(953). Similarly to the adjustment of the 953
maximum flow, other characteristics are
not changed.
However, remember that, if tightened too
much, the required horsepower during
the maximum delivery pressure(or during
relieving) may increase. R130MP02

Adjustment of min flow spring

Speed
Delivery flow, Q

Tightening amount Flow change

of adjusting screw amount
(953)

(min -1) (Turn) (ℓ/min)

1900 +1/4 -7 Delivery pressure, Pi

2-20
(5) Qmax cut control 647
The regulator regulates the maximum 648
delivery flow by inputting the pilot pressure 723
pm. Since this is a2-position control 642 43
method, the maximum delivery flow may
801
be switched in two steps by turning on/off 801
the oilot pressure Pm.(The maximum 924
control flow cannot be controlled in
intermediate level.) 641 730 643 708 644 645 646 728
① Functional explanation R360LC-7(2-4)

As shown in the figure, the pilot pressure

Pm switches the maximum flow in two
steps.

Delivery flow, Q
When the pilot pressure Pm is given, it is Pm
admitted to the lefthand side of the piston
QMC(648). The piston QMC moves the
stopper(647) and pilot piston(643) to the
right, overcoming the force of the pilot
spring(646), thereby reducing the delivery
flow of the pump. Pilot pressure, Pi
Since the adjusting screw QMC(642) is
provided with a flange, the piston QMC
stops upon contact with the flange, and
the position of the pilot piston at this time
determines the maximum flow of the
pump.

② Adjustment of Qmax cut flow

Adjust it by loosening the hexagon
nut(801) and by tightening(or loosening)
Delivery flow, Q

the adjusting screw QMC(642).

Tightening the screw decreases the
Qmax cut flow as shown in the figure.

Pilot pressure, Pi

2-21